Building for Better Sleep: A.R. Mays Completes Major Brooklyn Bedding Expansion

Nearly 300,000-square-foot addition increases foam production capacity while maintaining uninterrupted operations.

Glendale, AZ — A.R. Mays Construction has completed a significant expansion of Brooklyn Bedding's manufacturing operations in Glendale, Arizona, adding nearly 300,000 SF of new foam production capability to the company's existing facility. The project was designed to support Brooklyn Bedding's continued growth while allowing the existing plant to remain fully operational throughout construction.

The expansion included a 286,291 SF pre-engineered metal production facility and a 4,575 SF block structure known as Tank Farm 2, along with extensive site-wide infrastructure improvements. The new facilities substantially increase the company's production capacity and position Brooklyn Bedding for future growth and expanded market demand.

What made the project particularly unique was the scale of construction taking place alongside an active manufacturing operation. Throughout the duration of the project, Brooklyn Bedding's existing foam processing plant maintained full production capacity, requiring careful coordination between construction activities and ongoing operations.

"This project required a high level of collaboration and planning from day one," said the A.R. Mays project team. "Maintaining uninterrupted production while constructing nearly 300,000 SF of new manufacturing space demanded constant communication, detailed scheduling, and close coordination with the owner and project stakeholders."

The primary challenge was ensuring construction activities did not impact the operations of the existing facility. The project team addressed this through daily onsite coordination, weekly OAC meetings, and detailed scheduling efforts that allowed construction and manufacturing activities to operate simultaneously without disruption.

A key factor in the project's success was the decision to utilize a pre-engineered metal building system for the new foam and curing facility. Compared to a traditional concrete tilt-up structure, the pre-engineered metal building provided significant cost and schedule advantages while delivering the large-scale industrial space required for production operations.

Brooklyn Bedding successfully occupied the new facility with zero impacts to ongoing manufacturing operations. The completed expansion enhances the company's production capabilities and provides the infrastructure necessary to support continued growth for years to come.

The project's successful delivery reflects the strong partnership between Brooklyn Bedding, the design team, and A.R. Mays Construction, whose collaborative approach ensured both operational continuity and project success from start to finish.